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Numerical and experimental research on warm cross wedge rolling of hollow shafts with corrugated surface

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Abstract

HCWR (hot cross wedge rolling) of hollow shafts has been investigated while there are few investigations on CWR (cross wedge rolling) of hollow shafts at other temperatures. Because of the severe oxidative decarburization of HCWR and large deformation resistance of CCWR (cold cross wedge rolling), the WCWR (warm cross wedge rolling) was proposed for forming hollow shafts to compromise these limitations. In this paper, relevant investigations about a WCWR process of hollow shafts with corrugated surface were carried out. At first, the parameters and the geometry of the WCWR rollers of hollow shafts with corrugated surface were designed. Then, the finite element (FE) model of the WCWR process was established and verified by the laboratory test. Next, the FE results with various mandrel diameters were presented, and the influence of the mandrel diameter on the distribution of stress, effective strain, and temperature and the rolling force and torque was analyzed. Finally, the experiment results with various mandrel diameters were presented, and the effect of the mandrel diameter on the forming quality was discussed. The results show that as mandrel diameter increases, the temperature of the workpiece after rolling decreases, while the effective stress and strain and the rolling torque increase. The maximum dimensional deviation at the symmetric cross section is not larger than 0.3 mm when there is no mandrel or the relative mandrel diameter is 0.7, and the roundness is gradually worse as mandrel diameter increases.

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Funding

This work is funded by the National Natural Science Foundation of China (Grant No. 51875036). This work is supported by the National Key R&D Program of China (Grant number 2018YFB1307900). This work is also supported by the Beijing Laboratory of Modern Transportation Metal Materials and Processing Technology and the Beijing Key Laboratory of Metal Forming Lightweight.

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Authors and Affiliations

  1. School of Mechanical Engineering, University of Science and Technology Beijing, No. 30 Xueyuan Road, Haidian District, Beijing, 100083, China

    Jiaai Shi, Jinping Liu, Baoyu Wang & Jinxia Shen

  2. Engineering Research Center of Part Rolling, Ministry of Education, Beijing, 100083, China

    Jinping Liu & Baoyu Wang

Authors
  1. Jiaai Shi
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  2. Jinping Liu
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  3. Baoyu Wang
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  4. Jinxia Shen
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Contributions

All authors contributed to the study conception and design. Software, investigation, validation, and methodology were performed by Jiaai Shi. The first draft of the manuscript was also written by Jiaai Shi. The supervision, methodology, and writing (reviewing and editing) were performed by Jinping Liu. Project administration, supervision, and funding acquisition were performed by Baoyu Wang. The methodology and writing (reviewing and editing) were performed by Jinxia Shen. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Jinping Liu.

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This article is part of the Topical Collection: New Intelligent Manufacturing Technologies through the Integration of Industry 4.0 and Advanced Manufacturing

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Shi, J., Liu, J., Wang, B. et al. Numerical and experimental research on warm cross wedge rolling of hollow shafts with corrugated surface. Int J Adv Manuf Technol 122, 243–262 (2022). https://doi.org/10.1007/s00170-022-09379-7

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  • DOI: https://doi.org/10.1007/s00170-022-09379-7

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